Filter Element

ABSTRACT

A filter element, and filter apparatus, include a filter pack, a seal member, and a seal support frame operatively connecting the seal member to the filter pack. The seal support frame includes an annular extension, which is preferably canted at an oblique angle to a longitudinal axis, for supporting the seal member. The seal support frame also preferably includes a first end thereof including the annular extension, and a second end thereof spaced from the first end thereof along the longitudinal axis, with the first and second ends of the seal support frame joined by a hub of the outer peripheral sidewall of the seal support frame to define a cavity within the seal support frame for receiving the filter pack. The first and second ends of the seal support frame, and the filter pack are preferably joined and sealed to one another by a single bead of adhesive.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a continuation of co-pending U.S. patentapplication Ser. No. 10/979,876, filed Nov. 2, 2004, the entiredisclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to fluid filters, and more particularly tofilters having a housing adapted for receiving a filter elementincluding a seal member for sealing a juncture between the filterhousing and the filter element when the filter element is installed infilter housing.

BACKGROUND OF THE INVENTION

Filters of the type used for filtering particulate matter from fluidsometimes include a filter housing having an inlet for receiving thefluid with entrained particulate matter, and an outlet for deliveringthe filtered fluid to a device needing fluid that is free of particulatematter. For example, a filter may be provided at the air inlet of anengine or an air compressor to remove dust, water, or other particulatematter that could cause damage to the engine or compressor if it werenot removed from the air entering the engine or compressor.

In such filters, the particulate matter is typically removed by a filterelement that is installed within the filter housing in such a mannerthat the fluid must flow through a filter element, including a filterpack of porous filter material, which removes the particulate matterfrom the fluid. Over time, the filter pack of the filter element becomesplugged or coated with particulate matter, necessitating removal andreplacement of the filter element in order for the filter to continue inits function of supplying particulate-free fluid at the outlet of thehousing.

In order to facilitate removal and replacement of the filter element, itis known to configure the filter housing to include a generally tubularwall section thereof, and provide a seal member mounted on the filterelement that seals the juncture between an inner surface of the tubularwall section and the filter element, when the filter element is insertedinto the housing, so that the fluid cannot bypass the filter elementwhile flowing through the housing. Prior approaches to providing suchsealing arrangement are disclosed in U.S. Pat. No. 6,190,432, to Gieske,et al., and in U.S. Pat. No. 6,517,598 B2, to Anderson, et al.

It is desirable to provide an improved filter element, and filterapparatus, having a filter element and sealing arrangement that are morerobust than the arrangements used in prior filters. It is also desirableto provide such an improved filter element and filter apparatus in aform that can be manufactured in a more straight-forward and lower costmanner than prior filter elements and filter apparatuses.

BRIEF SUMMARY OF THE INVENTION

The invention provides an improved filter element and filter apparatusthrough use of a filter element that includes a filter pack, a sealmember, and a seal support frame operatively connecting the seal memberto the filter pack.

According to one aspect of the invention, the filter pack has first andsecond oppositely facing flow faces, and defines a longitudinal axispassing through the first and second flow faces. The seal support frameincludes a canted annular extension thereof, for supporting the sealmember. Having the seal support canted provides a more robust structurethat is more inherently capable of withstanding radial and axial forceson the seal member during installation, removal, and operation of thefilter element.

The canted annular extension projects from one of the first and secondflow faces at an oblique angle to the longitudinal axis, and has a firstend and a distal end thereof. The seal support frame further includes aninwardly canted intermediate annular segment that extends between thefirst end of the canted annular extension and the one of the first andsecond flow faces of the filter pack. The intersection of the first endof the canted annular extension and the inwardly canted intermediateannular section forms a V-shaped, outwardly opening, annular groove atthe juncture of the canted annular extension and the inwardly cantedintermediate annular segment.

According to another aspect of the invention, the filter pack has anouter periphery thereof joining first and second oppositely facing flowfaces, and defining a longitudinal axis passing through the first andsecond flow faces. The seal support frame has an outer peripheralsidewall, adapted for circumscribing the outer periphery of the filterpack. The seal support frame may also have a first end thereof includingan annular extension, and a second end thereof spaced from the first endthereof along the longitudinal axis, with the first and second ends ofthe seal support frame joined by the outer peripheral sidewall of theseal support frame to define a cavity within the seal support frame forreceiving the filter pack. Having the filter pack disposed in the cavityof the seal support frame provides significant additional protection forthe filter pack, during installation, removal, and operation of thefilter element.

According to a further aspect of the invention, the outer peripheralsidewall may include a first and a second section thereof, with thefirst section extending from one of the first or second ends of the sealsupport frame and terminating in a distal end of the first section ofthe outer peripheral sidewall, and the second section thereof extendingfrom the other of the first and second ends of the seal support frameand terminating in a distal end of the second section of the outerperipheral sidewall. The first and second sections of the outerperipheral sidewall are joined together by a hub extending from thedistal end of one of the first or second sections of the outerperipheral sidewall, with the hub being adapted for receiving the distalend of the other of the first and second sections of the outerperipheral sidewall.

The distal ends of the first and second sections of the outer peripheralside wall may be joined and sealed to the outer periphery of the filterpack by a single bead of adhesive forming a common bond and seal betweenthe distal ends of the first and second sections of the outer peripheralsidewall of the seal support frame and the outer periphery of the filterpack. Having the components of the filter element configured to allowuse of a single adhesive bead for simultaneously joining the first andsecond sections of the outer sidewall of the seal support member to oneanother and to the outer periphery of the filter pack, according to theinvention, significantly facilitates manufacture of the filter elementby eliminating the need for applying multiple adhesive beads as isrequired in the manufacture of prior filter elements.

The invention may take the form of a filter apparatus including ahousing and a filter element according to the invention. A filterelement or filter apparatus, according to the invention, may include afilter pack having a plurality of flutes of porous filter media, andadditional features for facilitating manufacture of a filter element orapparatus according to the invention. The invention may be practicedwith efficacy in filters using elements formed in a variety of crosssectional shapes including circular, race-track-like, oblong orrectangular.

Other aspects, objectives and advantages of the invention will beapparent from the following detailed description and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective partial cross-sectional view of a firstexemplary embodiment of the invention, in the form of a filter element,adapted for insertion into a filter housing, but not including thefilter housing;

FIG. 2 is an orthographic cross section of the exemplary embodiment ofFIG. 1;

FIG. 3 is an orthographic partial cross section of an outwardly cantedannular extension of a seal support frame of the exemplary embodiment ofFIGS. 1 and 2, with a seal member not shown, for clarity ofillustration;

FIG. 4 is an orthographic partial cross section of an outwardly cantedannular extension of a seal support frame of the exemplary embodiment ofFIGS. 1-3, that is identical to FIG. 3, but with the seal member shown;

FIG. 5 is a schematic cross section, similar to FIGS. 3 and 4,illustrating a method for molding the seal member onto the cantedannular extension;

FIGS. 6 and 7 are orthographic cross sections taken respectivelythrough, and between, raised locating ribs of the seal support frame;

FIG. 8 is a partial cross sectional view cutting transversely throughone of the raised ribs of FIB. 7, along line 8-8 of FIG. 7;

FIG. 9 is a perspective illustration of a fluted filter media, used inexemplary embodiments of the invention;

FIGS. 10 and 11 are perspective illustrations of optional crosssectional shapes for a filter pack, according to the invention;

FIG. 12 is an orthographic cross section of a second exemplaryembodiment of the invention, in the form of a filter apparatus includinga filter housing and a filter element adapted for attachment to thefilter housing; and

FIG. 13 is a partial orthographic cross section of an alternateembodiment of the invention, including an annular extension which iscanted inward.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show a first exemplary embodiment of the invention in theform of a filter element 100, adapted for insertion into a filterhousing, but not including the filter housing, for removing particulatematter from a flow of fluid passing through the filter housing. The termfluid as used herein is intended to include fluids in either liquid orgaseous forms. The exemplary embodiments shown herein specificallyillustrate an air filter of the type used for filtering intake air forengines and air compressors.

The filter element 100 includes a filter pack 102, a seal member 104,and a seal support frame 106 operatively connecting the seal member 104to the filter pack 102. The filter pack 102 includes first and secondoppositely facing flow faces 108, 110, and defines a longitudinal axis112 passing through the first and second flow faces 108, 110. The sealsupport frame 106 including a canted annular extension 114 thereof,projecting from the first flow face 108 at an oblique angle to thelongitudinal axis 112, for supporting the seal member 104.

The term “oblique,” is used herein in accordance with the commondictionary meaning of that word to indicate that the canted annularextension 114 extends at an angle, with respect to the longitudinal axis112, which is neither parallel nor perpendicular to the longitudinalaxis 112. The term “annular,” is also used herein, according to itscommon dictionary definition, to describe a variety of ring-like shapesdisposed about an axis or centerline. Annular shapes, as contemplated bythe inventors, may include, but are not limited to, shapes that areround, rectangular, oval, or race-track-like with two generally straightand parallel sides joined by rounded ends.

In the filter element 100 of the first exemplary embodiment, the cantedannular extension includes a first end 116 and a distal end 118 thereof,with the first end 116 of the canted annular extension 114 beingdisposed nearer than the distal end 118 thereof to both the longitudinalaxis 112 and the first flow face 108 of the filter pack 102, such thatthe canted annular extension 114 is canted outward from the longitudinalaxis 112.

The canted annular extension 114 includes a plurality of holes 120extending therethrough, as best seen in FIG. 3, with the seal member 104including a portion thereof extending through the holes 120 in thecanted annular extension 114, as shown in FIG. 4, to help retain theseal member 104 on the canted annular extension 114. The seal supportframe 106 of the filter element 100 also includes an inwardly cantedintermediate annular segment 122 extending between the first end 116 ofthe canted annular extension 114 and the first flow face 108 of thefilter pack 102, to thereby form a V-shaped, outwardly opening, annulargroove 124 at the juncture of the canted annular extension 106 and theinwardly canted intermediate annular segment 122, for receipt therein ofa portion 126 of the seal member 104.

As shown in FIG. 5, the seal member 104 in the filter element 100 ispreferably formed from a material such as urethane foam, molded onto thecanted annular extension 114 using a mold 128. During molding of theseal member 104, the filter element is placed into the mold 128 with thecanted annular extension 114 facing downward, as shown in FIG. 5. Amaterial used for forming the seal member 114 is placed in the mold 128and allowed to foam and rise up around the canted annular extension 114,and through the holes 120 into the V-shaped groove 124 of the sealsupport frame 106. The canted annular extension 114 defines an innersurface 130 thereof, having a raised annular rib 132 extending therefromfor contacting and sealing against the mold 128, to thereby limit theextent of the seal member 104 along the inner surface 130 of the cantedannular extension 114.

As shown in FIGS. 1 and 2, the filter pack 102 defines an outerperiphery 134 thereof, and the seal support frame includes an outerperipheral sidewall 136 thereof adapted for circumscribing the outerperiphery 134 of the filter pack 102. The seal support frame 106includes a first end 138 thereof including the canted annular extension114, and a second end 140 thereof, spaced from the first end thereofalong the longitudinal axis 112. Each of the first and second ends 138,140 of the seal support frame 106 include a skirt section thereof, whichare joined together to form the outer peripheral sidewall 136 of theseal support frame 106, and to define a cavity 141 within the sealsupport frame 106 for receiving the filter pack 102. The first andsecond ends 138, 140 of the seal support frame are further configuredsuch that, when the first and second ends 138, 140 of the seal supportframe 106 are joined to one another, the filter pack 102 is retainedwithin the cavity 141 of the seal support frame 106.

In the exemplary embodiment of the filter element 100, the first andsecond ends 138, 140 of the seal support frame 106 are joined to oneanother and sealed to the outer periphery 134 of the filter pack 106 bya single annular bead of adhesive 142, as best seen in FIGS. 6 and 7.The single annular bead of adhesive 142 performs the dual functions ofsimultaneously joining the first and second ends 138, 140 of the sealsupport frame 106 to the outer periphery 134 of the filter pack 106, andproviding a seal blocking fluid flow between the outer periphery 134 ofthe filter pack 102 and an inner surface of the peripheral annularsidewall 136. In other embodiments of the invention, more than one beadof sealant may be used, or one or more non-continuous beads of sealantmay be used. It is contemplated, however, that use of a single annularbead of adhesive 142 will generally be preferred, because the singleannular bead 142 performing multiple functions will typically facilitatemanufacture and reduce costs, in most embodiments of the invention.

By virtue of the construction of the seal support frame 106 of thefilter 100, the outer peripheral sidewall 136 includes a first section144 thereof extending from the first end 138 of the seal support frame106, and terminating in a distal end 146 of the first section 144 of theouter peripheral sidewall 136. The outer peripheral sidewall 136 alsoincludes a second section 148 thereof, that extends from the second end140 of the seal support frame 106 and terminates in a distal end 150 ofthe second section 148 of the outer peripheral sidewall 106.

The first and second sections 144, 148 of the outer peripheral sidewall136 are joined together with a joint formed by a hub 152 integrallyformed with and extending from the distal end 146 of the first section144 of the outer peripheral sidewall 136, with the hub 152 being adaptedfor receiving the distal end 150 of the second section 148 of the outerperipheral sidewall 136. The hub 152 is configured such that an innersurface 154 of the hub 152, is spaced from the distal end 150 of thesecond section 148 of the outer peripheral sidewall 136 to form a gapfor receiving a portion of the bead of adhesive 142.

As shown by FIGS. 6-8, in the seal support frame 106 of the exemplaryembodiment of the filter element 100, the second section 148 of theouter peripheral sidewall 136 includes a plurality of raised ribs 156that extend outward from the second section 148 of the outer peripheralsidewall 136, adjacent the distal end 150 of the second section 148 ofthe outer peripheral sidewall 136, for spacing the inner surface 154 ofthe hub 152 from the distal end 150 of the second section 148 of theouter peripheral sidewall 136 of the seal support frame 106. The ribs156 ensure that a gap of a predetermined size will be maintained betweenthe inner surface 154 of the hub 152 and the distal end 150 of thesecond section 148 of the outer peripheral sidewall 136 to allow aportion of the bead of adhesive 142 to remain in the gap when the firstand second ends 138, 140 of the seal support frame 106 are joined to oneanother and to the outer periphery 134 of the filter pack 102.

In the exemplary embodiment of the filter element 100, the ribs 156 alsoperform a second function, by being sized to provide a press fit of thedistal end 150 of the second section 148 of the outer peripheralsidewall 136 into the hub 152. The press fit allows the seal supportframe 106 to be self-fixturing, to that once the first and second ends138, 140 of the seal support frame 106 are pressed together to a desiredheight, the press fit will hold the first and second ends 138, 140together at the desired height while the adhesive 142 is curing. Thisallows the filter element 100 to be removed from any press equipmentused for assembly, and set aside for curing of the adhesive, therebyfreeing up the press equipment for use in assembling another filterelement 100.

The hub 152, the distal end 150 of the second section 148 of the outerperipheral side wall 136, and the outer periphery 134 of the filter pack102 are preferably joined to one another, after the filter pack 102 isinserted into the portion the cavity 141 formed by the first end 138 ofthe seal support frame 106, by placing a single bead of adhesive 142, ofa judiciously selected size, at the juncture of the distal end 146 ofthe first section 144 of the peripheral sidewall 136 and the hub 152 andthe outer periphery of the filter pack 102, prior to inserting thedistal end 150 of the second section 148 of the peripheral sidewall 136into the hub 152. After placement of the bead of adhesive 142 in the hub152, the distal end 150 of the second section 148 of the peripheralsidewall 136 is then inserted into the hub 152, and pressure is appliedto the second end 140 of the seal support frame 106 to urge it intocontact with the second face 110 of the filter pack 102, and to push thedistal end 150 of the second section 148 into the hub 152. As the distalend 150 of the second section of the peripheral sidewall 136 moves intothe hub 152, the adhesive forming the single bead of adhesive 142 issqueezed into gaps between an inner surface 154 of the hub 152, that isspaced from the distal end 150 of the second section 148 of the outerperipheral sidewall 136 to form a space for receiving an adhesivesealant for joining together the distal ends of the first and secondsections of the outer peripheral sidewall. Once the distal end 150 ofthe second section 148 of the peripheral sidewall 136 has been pressedfar enough into the hub 152 to achieve a desired overall height of thefilter element 100, the press fit features described above allow thefilter element 100 to be self-fixturing while the adhesive 142 iscuring.

The components of the filter element 100 need not, however, be assembledin the same order, or by the method described above, in practicing theinvention. It will be understood, by those having skill in the art, thatin other embodiments of the invention, other arrangements, sequences, ormethods may be used for forming and/or joining together component partsof a seal support frame, according to the invention. In otherembodiments of the invention, for example, it may be desirable to have afilter pack captured within a seal support frame, according to theinvention, but to not have the outer periphery joined to the sealsupport frame by an adhesive. It will also be understood that, althoughthe outer peripheral sidewall 136 of the seal support frame 106 of theexemplary embodiment the filter element 100 is imperforate, in otherembodiments of the invention the outer peripheral sidewall may includeone or more openings extending therethrough.

As shown in FIG. 1, the first and second ends 138, 140 of the sealsupport frame 106 of the exemplary embodiment of the filter element 100also respectively include a first end flow face screen 137 and a secondend flow face screen 139, that provide protection against physicaldamage for the first and second flow faces 108, 110 of the filter pack102. The first and second flow face screens 137, 139 also serve toresist forces on the filter pack 102 that are exerted in a directionparallel to the longitudinal axis 112 by fluid flowing through thefilter pack 102. In the exemplary embodiment of the filter element 100,the first and second flow face screens 137, 139 are formed integrallywith the seal support frame 106. In other embodiments of the invention,however, such flow face screens may be separate components, attached toor held in place by the seal support frame, or may be eliminated.

Those having skill in the art will recognize that in embodiments of theinvention having a canted annular extension, as described above, thecanted extension provides a convoluted ring-like structure that isinherently stiff in the radial direction, for resisting compressionforces imposed on the seal member when the filter element is insertedinto a housing. As a result of this inherent stiffness, it is notnecessary, in some embodiments of the invention, for the flow facescreens 137, 139 to provide appreciable radial stiffening of the sealsupport.

The filter pack 102 of the exemplary embodiment of the filter element100 is formed from a filter media 157, as shown in FIG. 9, that includesa convoluted sheet 158 of porous filter material, for removingparticulate matter from a fluid that is directed through the filterelement 100. The convoluted sheet 158 may be formed by any appropriateprocess, such as corrugating or pleating, but preferably by gathering,as described in a United States patent application, entitled “GatheredFilter Media and Method of Making Same,” bearing the attorney docket no.502854, assigned to the Assignee of the present invention, filedconcurrently herewith and incorporated herein by reference.

The convoluted sheet 158 of porous filter material, of the filter media157, forms a plurality of contiguous adjacent convolutions 160, commonlyknown in the industry as flutes. Selected ends of the flutes 160 of thefilter media 157 may be blocked, with a bead of adhesive for example, tocause fluid entering one end of some of the flutes 160 to flow throughthe porous filter media into other flutes 160 prior to exiting thefilter media 157 at an opposite end of the flutes 160, in the mannerknown in the art. Selected flutes may also include an intermediate seal161, as disclosed in a United States patent application, entitled“Fluted Filter Media with Intermediate Flow Restriction and Method ofMaking Same,” bearing the attorney docket no. 502852, assigned to theAssignee of the present invention, filed concurrently herewith andincorporated herein by reference.

The fluted filter media 157 of the exemplary embodiment of the filterelement 100 also includes a face sheet 162 attached to the convolutedsheet 158, for retaining the convoluted sheet 158 of porous filtermaterial in a convoluted state. The term face sheet, as used herein, isintended to encompass any form of sheet or strip of generally flat,porous or non-porous, material attached to the convoluted sheet 158 ofporous filter material. In the exemplary embodiment, it is contemplatedthat the face sheet 162 would preferably be formed of a porous filtermaterial, in most embodiments of the invention.

As shown in FIG. 10, the filter pack 102 of the exemplary embodiment ofthe filter element 100 described above, is formed by coiling the filtermedia 157 to form a generally right-circular-cylinder-shaped structure,that is proportioned for insertion into a filter housing having agenerally circular cross section. In other embodiments of the invention,however, a filter pack 102′, and its associated filter element (notshown), may have a non-circular cross section, such as the race-trackshaped filter shown in FIG. 11. Filter packs having other crosssectional shapes, such as square, rectangular, or polygonal, forexample, may also be utilized, in other embodiments of the invention, bycoiling or bonding together successive layers of a fluted filter media.It is also understood that the invention is not limited to filter packsof fluted filter media. Those having skill in the art will readilyrecognize that the invention may also be practiced with efficacy, usingother types of filter media.

FIG. 12 shows a second exemplary embodiment of the invention, in theform of a filter apparatus 200, having a filter housing assembly 202including a filter housing 204 and a boot 206, adapted for attachmentthereto of a filter element 208. The filter element 208 is of thecartridge type described herein. In contrast to the first exemplaryembodiment of the invention, however, in which the filter apparatusincluded only the filter element 100, and not the filter assembly towhich the filter element 100 is adapted to be attached, the secondexemplary embodiment of the invention includes both the filter element208 and the filter assembly 202 formed by the housing 204 and the boot206. It should be further noted that the filter apparatus 200 of thesecond exemplary embodiment also includes a safety filter 210, mountedin the filter housing 204 at a point in the fluid flowpath downstreamfrom the filter cartridge 208. Other embodiments of a filter apparatus,according to the invention, may include fewer or more components thanthe filter assembly 200 of the second exemplary embodiment.

The filter element 208 of the filter apparatus 200 is generally of thetype described above in relation to the first exemplary embodiment.Specifically, the filter element 208 of the filter apparatus 200includes a generally right-circular-cylinder shaped filter pack 212 offluted filter media, and a seal support frame 214 having an outwardlycanted annular extension 216 supporting a seal member 218 molded to theoutwardly canted extension 216, in the same manner as described above inrelation to the filter element 100 of the first exemplary embodiment.The seal support frame 214 of the filter element 208 of the filterapparatus 200 of the second exemplary embodiment is also a two partstructure including a hub arrangement 220 for joining an upper framesection 222 and a lower frame section 224 (as oriented in FIG. 12)together and to the outer periphery of the filter pack with a singleannular bead of adhesive (not shown) in the same manner as describedabove in relation to the first exemplary embodiment of the invention.

Those having skill in the art will recognize that, although inventionhas been described herein with reference to several exemplaryembodiments, many other embodiments of the invention are possible. Forexample, as shown in FIG. 13, in other embodiments of invention, afilter element 300 may include an annular extension 302 that is cantedinward, rather than being canted outward as shown and described inrelation to the first and second exemplary embodiments of the inventiondescribed above. Such an inwardly canted annular extension may or maynot include through holes for receiving and retaining a portion of aseal member 304 molded, in situ, onto the annular extension 302. Thosehaving skill in the art will recognize that having the annular extension302 canted inward results in the distal end of the annular extension 302having a smaller periphery than the portion of the annular extensionadjacent the flow face 306 of the filter pack 308. As a result of thisconstruction, insertion and removal of the filter element 300 isfacilitated by having the compressive forces on the seal 304 begenerally proportional to the axial engagement length of the seal member304 with an inside wall of a housing (not shown).

As shown in FIGS. 2 and 13, a seal member 104, 304 according to theinvention may include a lead in chamfer 105, 305 to facilitate insertionof a filter element 100, 300, according to the invention, into a filterhousing. It is also understood that, in an embodiment of the invention,the seal member may or may not be fixedly attached to the annularextension of a seal support frame according to the invention.

It is also contemplated that an embodiment of the invention including aseal support frame having an outer peripheral sidewall, adapted forcircumscribing the outer periphery of the filter pack, a first endthereof including an annular extension, and a second end thereof spacedfrom the first end thereof along the longitudinal axis, with the firstand second ends of the seal support frame joined by the outer peripheralsidewall of the seal support frame to define a cavity within the sealsupport frame for receiving the filter pack, may include an annularextension which is not canted either inward or outward.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1.-96. (canceled)
 97. A filter element, comprising: a fluted filter media pack comprising a fluted sheet and a face sheet that are secured together and wound up, the fluted filter media pack having a plurality of flutes including a first set of flutes that are closed proximate a first flow face and a second set of flutes that are closed proximate a second flow face, a seal support disposed over the second flow face, the seal support including an annular extension having a distal end, and inner and outer surfaces defined on opposing sides of the distal end, an annular seal member molded around the annular extension to include portions along the inner surface and the outer surface, the portion of the annular seal member that is over the outer surface providing an annular sealing surface; and an annular rib integral with the seal support and projecting from the inner surface in a different direction than a direction of the annular extension, the annular rib disposed axially between the distal end and the second flow face.
 98. The filter element of claim 97, wherein the annular seal member is molded of a foamed urethane material, the annular rib being continuous around the inner surface for preventing free rise of the foamed urethane material axially past the annular rib along the inner surface.
 99. The filter element of claim 97, wherein the annular rib defines a smaller inner perimeter than an inner perimeter of the annular seal member.
 100. The filter element of claim 97, wherein the annular rib has generally inclined surfaces that are inclined toward each other as the inclined surfaces project away from the inner surface.
 101. The filter element of claim 101, wherein the annular rib has a generally triangular cross section.
 102. The filter element of claim 97, further including a flow face screen integral with the seal support extending over the second flow face, the flow face screen disposed axially between the annular rib and the second flow face.
 103. The filter element of claim 97, wherein the seal support further includes a canted annular segment joined to the annular extension at a corner and extending generally between the second flow face and the annular extension.
 104. The filter element of claim 103, wherein the seal support further includes an annular sidewall joined to the canted annular segment, the annular sidewall extending around an outer periphery of the fluted filter media pack.
 105. The filter element of claim 97, wherein the annular rib is arranged and positioned to contact a mold for the filter element.
 106. The filter element of claim 97, wherein the seal support is arranged on an outlet side of the filter element.
 107. A filter element and housing assembly, comprising: a housing having an annular sidewall with an interior surface; a filter element installed in the housing, the filter element including: a fluted filter media pack comprising a fluted sheet and a face sheet that are secured together and wound up, the fluted filter media pack having a plurality of flutes including a first set of flutes that are closed proximate a first flow face and a second set of flutes that are closed proximate a second flow face, a seal support disposed over the second flow face, the seal support including an annular extension having a distal end; an annular seal member molded around the annular extension providing an annular sealing surface radially sealing against and engaging the interior surface of the housing; and an annular rib integral with the seal support and projecting from the seal support on a side of the seal support opposite the side of the annular sealing surface, the annular rib disposed axially between the distal end and the second flow face.
 108. The filter element of claim 107, wherein the annular seal member is molded of a foamed urethane material, the annular rib being continuous around an inner surface of the annular extension for preventing free rise of the foamed urethane material axially past the annular rib along the inner surface.
 109. The filter element of claim 108, wherein the annular rib defines a smaller inner perimeter than an inner perimeter of the annular seal member.
 110. The filter element of claim 109, wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension and wherein the annular rib has generally inclined surfaces that are inclined toward each other as the inclined surfaces project away from the inner surface.
 111. The filter element of claim 11 0, wherein the annular rib has a generally triangular cross section.
 112. A filter element, comprising: a fluted filter media pack comprising a fluted sheet and a face sheet that are secured together and wound up, the fluted filter media pack having a plurality of flutes including a first set of flutes that are closed proximate a first flow face and a second set of flutes that are closed proximate a second flow face, a seal support disposed over the second flow face, the seal support including an annular extension having a distal end, and inner and outer surfaces defined on opposing sides of the distal end, an annular seal member molded around the annular extension to include a portion over the outer surface providing an annular sealing surface; and an annular rib integral with the seal support, the annular rib disposed axially between the distal end and the second flow face and defining a smaller inner perimeter than an inner perimeter of the annular seal member.
 113. The filter element of claim 112, wherein the annular seal member is molded of a foamed urethane material, the annular rib being continuous around the inner surface for preventing free rise of the foamed urethane material axially past the annular rib along the inner surface.
 114. The filter element of claim 113, wherein the annular rib is pointed in a direction that is different than an extending direction of the annular extension and wherein the annular rib has generally inclined surfaces that are inclined toward each other as the inclined surfaces project away from the inner surface.
 115. The filter element of claim 114, wherein the annular rib has a generally triangular cross section.
 116. The filter element of claim 112, further including a flow face screen integral with the seal support extending over the second flow face, the flow face screen disposed axially between the annular rib and the second flow face, and wherein the seal support further includes a canted annular segment joined to the annular extension at a corner and extending generally between the second flow face and the annular extension, the flow face screen intersecting the canted annular segment. 